Water/wastewater recycle and reuse with plasma, activated carbon and energy system

ABSTRACT

The present invention provides a system that includes a glow discharge cell and a plasma arc torch. A first valve is connected to a wastewater source. An eductor has a first inlet, a second inlet and an outlet, wherein the first inlet is connected to the outlet of the electrically conductive cylindrical vessel, the second inlet is connected to the first valve, and the outlet is connected to the tangential inlet of the plasma arc torch. A second valve is connected between the tangential outlet of the plasma arc torch and the inlet of the glow discharge cell, such that the plasma arc torch provides the electrically conductive fluid to the glow discharge cell and the glow discharge cell provides a treated water via the outlet centered in the closed second end.

PRIORITY CLAIM AND CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to and is a divisionalapplication of U.S. patent application Ser. No. 14/216,892 filed on Mar.17, 2014, now U.S. Pat. No. 9,230,777, which is: (1) a non-provisionalpatent application of U.S. Provisional Patent Application Ser. No.61/787,185 filed on Mar. 15, 2013; and (2) a continuation-in-part ofU.S. patent application Ser. No. 13/586,449 filed on Aug. 15, 2012, nowU.S. Pat. No. 9,111,712 which is a continuation application of U.S.patent application Ser. No. 12/371,575 filed on Feb. 13, 2009, now U.S.Pat. No. 8,278,810, which is: (a) a continuation-in-part application ofU.S. patent application Ser. No. 12/288,170 filed on Oct. 16, 2008,which is a non-provisional application of U.S. Provisional PatentApplication Ser. No. 60/980,443 filed on Oct. 16, 2007 and U.S.Provisional Patent Application Ser. No. 61/028,386 filed on Feb. 13,2008; (b) a continuation-in-part application of U.S. patent applicationSer. No. 12/370,591 filed on Feb. 12, 2009, now U.S. Pat. No. 8,074,439,which is non-provisional patent application of U.S. Provisional PatentApplication Ser. No. 61/027,879 filed on Feb. 12, 2008; and (c) anon-provisional patent application of U.S. Provisional PatentApplication Ser. No. 61/028,386 filed on Feb. 13, 2008.

The entire contents of the foregoing applications are herebyincorporated herein by reference. This application is also related toU.S. Pat. No. 7,422,695 and U.S. Pat. No. 7,857,972 and multiple patentsand patent application that claim priority thereto.

FIELD OF THE INVENTION

The present invention relates generally to solid oxide electrolysiscells and plasma torches. More specifically, the present inventionrelates to a water/wastewater recycle and reuse with plasma, activatedcarbon and energy system.

BACKGROUND OF THE INVENTION

Glow discharge and plasma systems are becoming ever more present withthe emphasis on renewable fuels, pollution prevention, clean water andmore efficient processing methods. Glow discharge is also referred to aselectro-plasma, plasma electrolysis and high temperature electrolysis.In liquid glow discharge systems a plasma sheath is formed around thecathode located within an electrolysis cell.

U.S. Pat. No. 6,228,266 discloses a water treatment apparatus using aplasma reactor and a method of water treatment. The apparatus includes ahousing having a polluted water inlet and a polluted water outlet; aplurality of beads (e.g., nylon and other plastic type beads) filledinto the interior of the housing; a pair of electrodes, one of theelectrodes contacting with the bottom of the housing, another of theelectrodes contacting an upper portion of the uppermost beads; and apulse generator connected with the electrodes by a power cable forgenerating pulses. Some drawbacks of the '266 plasma reactor are therequirements of an extremely high voltage pulse generator (30 KW to 150KW), a plurality of various beads in a web shape and operating thereactor full from top to bottom. Likewise, the plasma reactor is notdesigned for separating a gas from the bulk liquid, nor can it recoverheat or generate hydrogen. In fact, the addition of air to the plasmareactor completely defeats the sole purpose of current research forgenerating hydrogen via electrolysis or plasma or a combination of both.If any hydrogen is generated within the plasma reactor, the addition ofair will cause the hydrogen to react with oxygen and form water. Also,there is no mention of any means for generating heat by cooling thecathode. Likewise, there is no mention of cooking organics unto thebeads, nor the ability to reboil and concentrate liquids (e.g., spentacids, black liquor, etc.), or recovering caustic and sulfides fromblack liquor.

The following is a list of prior art similar to the '266 patent:

Pat. No. Title 481,979 Apparatus for electrically purifying water501,732 Method of an apparatus for purifying water 3,798,784 Process andapparatus for the treatment of moist materials 4,265,747 Disinfectionand purification of fluids using focused laser radiation 4,624,765Separation of dispersed liquid phase from continuous fluid phase5,019,268 Method and apparatus for purifying waste water 5,048,404 Highpulsed voltage systems for extending the shelf life of pumpable foodproducts 5,326,530 High pulsed voltage systems for extending the shelflife of pumpable food products 5,348,629 Method and apparatus forelectrolytic processing of materials 5,368,724 Apparatus for treating aconfined liquid by means of a pulse electrical discharge 5,655,210Corona source for producing corona discharge and fluid waste treatmentwith corona discharge 5,746,984 Exhaust system with emissions storagedevice and plasma reactor 5,879,555 Electrochemical treatment ofmaterials 6,007,681 Apparatus and method for treating exhaust gas andpulse generator used therefor

Plasma arc torches are commonly used by fabricators, machine shops,welders and semi-conductor plants for cutting, gouging, welding, plasmaspraying coatings and manufacturing wafers. The plasma torch is operatedin one of two modes—transferred arc or non-transferred arc. The mostcommon torch found in many welding shops is the transferred arc plasmatorch. It is operated very similar to a DC welder in that a groundingclamp is attached to a workpiece. The operator, usually a welder,depresses a trigger on the plasma torch handle which forms a pilot arcbetween a centrally located cathode and an anode nozzle. When theoperator brings the plasma torch pilot arc close to the workpiece thearc is transferred from the anode nozzle via the electrically conductiveplasma to the workpiece. Hence the name transferred arc. Thenon-transferred arc plasma torch retains the arc within the torch. Quitesimply the arc remains attached to the anode nozzle. This requirescooling the anode. Common non-transferred arc plasma torches have a heatrejection rate of 30%. In other words, 30% of the total torch power isrejected as heat.

A major drawback in using plasma torches is the cost of inert gases suchas argon and hydrogen. There have been several attempts for forming theworking or plasma gas within the torch itself by using rejected heatfrom the electrodes to generate steam from water. The objective is toincrease the total efficiency of the torch as well as reduce plasma gascost. However, there is not a single working example that can runcontinuous duty. For example, the Multiplaz torch (U.S. Pat. Nos.6,087,616 and 6,156,994) is a small hand held torch that must bemanually refilled with water. The Multiplaz torch is not a continuoususe plasma torch.

Other prior art plasma torches are disclosed in the following patents.

Pat. No. Title 3,567,898 Plasma cutting torch 3,830,428 Plasma torches4,311,897 Plasma arc torch and nozzle assembly 4,531,043 Method of andapparatus for stabilization of low-temperature plasma of an arc burner5,609,777 Electric-arc plasma steam torch 5,660,743 Plasma arc torchhaving water injection nozzle assembly

U.S. Pat. No. 4,791,268 discloses “an arc plasma torch includes amoveable cathode and a fixed anode which are automatically separated bythe buildup of gas pressure within the torch after a current flow isestablished between the cathode and the anode. The gas pressure draws anontransferred pilot arc to produce a plasma jet. The torch is thuscontact started, not through contact with an external workpiece, butthrough internal contact of the cathode and anode. Once the pilot arc isdrawn, the torch may be used in the nontransferred mode, or the arc maybe easily transferred to a workpiece. In a preferred embodiment, thecathode has a piston part which slidingly moves within a cylinder whensufficient gas pressure is supplied. In another embodiment, the torch isa hand-held unit and permits control of current and gas flow with asingle control.”

Typically, and as disclosed in the '268 patent, plasma torch gas flow isset upstream of the torch with a pressure regulator and flow regulator.In addition to transferred arc and non-transferred arc, plasma arctorches can be defined by arc starting method. The high voltage methodstarts by using a high voltage to jump the arc from the centered cathodeelectrode to the shield nozzle. The blow-back arc starting method issimilar to stick welding. For example, similar to a welder touching agrounded work-pieced then pulling back the electrode to form an arc, ablow-back torch uses the cutting gas to push the negative (−) cathodeelectrode away from the shield nozzle. Normally, in the blow-back torcha spring or compressed gas pushes the cathode towards the nozzle so thatit resets to the start mode when not in operation.

The '268 plasma torch is a blow-back type torch that uses the contactstarting method. Likewise, by depressing a button and/or trigger acurrent is allowed to flow through the torch and thus the torch is in adead-short mode. Immediately thereafter, gas flowing within a blow-backcontact starting torch pushes upon a piston to move the cathode awayfrom the anode thus forming an arc. Voltage is set based upon themaximum distance the cathode can be pushed back from the anode. Thereare no means for controlling voltage. Likewise, this type of torch canonly be operated in one mode—Plasma Arc. Backflowing material throughthe anode nozzle is not possible in the '268 plasma torch. Moreover,there is no disclosure of coupling this torch to a solid oxide glowdischarge cell.

U.S. Pat. No. 4,463,245 discloses “A plasma torch (40) comprises ahandle (41) having an upper end (41B) which houses the componentsforming a torch body (43). Body (33) incorporates a rod electrode (10)having an end which cooperates with an annular tip electrode (13) toform a spark gap. An ionizable fuel gas is fed to the spark gap via tube(44) within the handle (41), the gas from tube (44) flowing axiallyalong rod electrode (10) and being diverted radially through apertures(16) so as to impinge upon and act as a coolant for a thin-walledportion (14) of the annular tip electrode (13). With this arrangementthe heat generated by the electrical arc in the inter-electrode gap issubstantially confined to the annular tip portion (13A) of electrode(13) which is both consumable and replaceable in that portion (13A) issecured by screw threads to the adjoining portion (13B) of electrode(13) and which is integral with the thin-walled portion (14).” Onceagain there is no disclosure of coupling this torch to a solid oxideglow discharge cell.

The following is a list of prior art teachings with respect to startinga torch and modes of operation.

Pat. No. Title 2,784,294 Welding torch 2,898,441 Arc torch push starting2,923,809 Arc cutting of metals 3,004,189 Combination automatic-startingelectrical plasma torch and gas shutoff valve 3,082,314 Plasma arc torch3,131,288 Electric arc torch 3,242,305 Plasma retract arc torch3,534,388 Arc torch cutting process 3,619,549 Arc torch cutting process3,641,308 Plasma arc torch having liquid laminar flow jet for arcconstriction 3,787,247 Water-scrubber cutting table 3,833,787 Plasma jetcutting torch having reduced noise generating characteristics 4,203,022Method and apparatus for positioning a plasma arc cutting torch4,463,245 Plasma cutting and welding torches with improved nozzleelectrode cooling 4,567,346 Arc-striking method for a welding or cuttingtorch and a torch adapted to carry out said method

High temperature steam electrolysis and glow discharge are twotechnologies that are currently being viewed as the future for thehydrogen economy. Likewise, coal gasification is being viewed as thetechnology of choice for reducing carbon, sulfur dioxide and mercuryemissions from coal burning power plants. Renewables such as windturbines, hydroelectric and biomass are being exploited in order toreduce global warming.

Water is one of our most valuable resources. Copious amounts of waterare used in industrial processes with the end result of producingwastewater. Water treatment and wastewater treatment go hand in handwith the production of energy. When discussing water and energy withinthe same text it is commonly referred to as the water-energy nexus. Ittakes energy to produce water and it takes water to produce energy. Evenrenewable energy such as solar and wind require water, within theconfines of manufacturing the photovoltaic panels, turbines, batteriesand ancillary equipment required to generate, transfer and deliverrenewable energy. Hence, the term Water-Energy Nexus.

The Water-Food Nexus is a rapidly emerging Worldwide issue, because bothare required for all forms of life—plants and animals—for survival.Thus, drinking water sources for animals and irrigation water sourcesfor plants that are stressed in drought stricken regions are now in direneed of reusing and recyling every drop of water, including black waterfrom flushed toilets to effluent from wastewater treatment plants toponds and tanks that animals wade into to stay cool. It is quite evidentthat drought stricken countries and regions would also benefit from asimple, inexpensive and energy efficient/recovery Point Of Use (“POE”),Point Of Entry (“POE”) and Safe Drinking Water Storage (“SWS”) system.

Therefore, there is a need for an advanced water treatment system forexisting drinking water and wastewater treatment plants that alsoproduces energy while producing a wastewater effluent safe for recyclingas irrigation water and/or drinking water for livestock. Morespecifically, worldwide water treatment and wastewater treatmentfacilities are in dire need of a sustainable solution for onsitegeneration of energy for aeration, pumping, mixing and disinfectingwater. A water/wastewater treatment system that could convert solid,liquid and/or gas carbonaceous matter from biomass and/or fossil fuelsto rotational energy and char, such as biochar, charcoal, carbon black,black carbon and/or activated carbon, while providing UV Light and Ozone(O₃) for disinfection and advanced water treatment would open the doorto a solution for the water and energy crisis facing the world.

SUMMARY OF THE INVENTION

In one embodiment, the present invention provides an advanced watertreatment system for existing drinking water and wastewater treatmentplants that also produces energy while producing a wastewater effluentsafe for recycling as irrigation water and/or drinking water forlivestock. In another embodiment, the present invention provides asustainable solution for onsite generation of energy for aeration,pumping, mixing and disinfecting water. In yet another embodiment of thepresent invention, a water/wastewater treatment system can convertsolid, liquid and/or gas carbonaceous matter from biomass and/or fossilfuels to rotational energy and char, such as biochar, charcoal, carbonblack, black carbon and/or activated carbon, while providing UV Lightand Ozone (O₃) for disinfection and advanced water treatment.

The present invention provides a means for coupling char production,energy recovery, UV Light, Ozone Generation, Activated Carbon Filtrationand both activation and reactivation of Char. Energy recovery may be inthe form of hot gases, hot water, steam generation, electricalgeneration, air or gas sparging, and/or rotational energy. Morespecifically, the present invention provides a means for plasmathermolytic char production, rotational energy, UV Light, OzoneGeneration and Activated Carbon Filtration with reduced to near ZERO airemissions. The rotational energy may be used for rotating a compressor,pump, mixer, auger, press, shredder, electrical generator, alternatorand/or any purpose that requires the use of rotational energy as a meansfor doing work. Very specifically, the present invention provides aplasma thermolytic means for converting Biomass to Plasma BioChar™ forcarbon filtration purposes, while producing UV Light and Ozone from anelectrical arc, in addition to converting and recovering the volatilegases from the plasma thermolytic conversion process into rotationalenergy, mixing and/or thermal energy. Concurrently, the presentinvention provides a means for pH control by directly mixing combustiongases produced from combustion of the volatile gases in addition, toproduction of acids and bases via glow discharge electrolysis for bothpH control as well as carbon activation. In addition, the presentinvention provides a means for producing sodium hypochlorite (“bleach”)for disinfection of drinking water as well as maintaining a freechlorine residual. The present invention includes a means for couplingwater and wastewater treatment with generating and storage of renewableenergy. Likewise, the present invention provides a means for couplingsolar and wind energy generation with water treatment for solving a direneed in wind and solar power—load smoothing and ramp rate mitigation.

The present invention provides a system that includes a glow dischargecell and a plasma arc torch. The glow discharge cell includes anelectrically conductive cylindrical vessel having a first end and aclosed second end, an inlet proximate to the first end, and an outletcentered in the closed second end, a hollow electrode aligned with alongitudinal axis of the electrically conductive cylindrical vessel andextending at least from the first end into the electrically conductivecylindrical vessel, wherein the hollow electrode has an inlet and anoutlet, a first insulator that seals the first end of the electricallyconductive cylindrical vessel around the hollow electrode and maintainsa substantially equidistant gap between the electrically conductivecylindrical vessel and the hollow electrode, and a non-conductivegranular material disposed within the substantially equidistant gap,wherein the non-conductive granular material allows an electricallyconductive fluid to flow between the electrically conductive cylindricalvessel and the hollow electrode, and the combination of thenon-conductive granular material and the electrically conductive fluidprevents electrical arcing between the cylindrical vessel and the hollowelectrode during an electric glow discharge. The plasma arc torchincludes a cylindrical vessel having a first end and a second end, atangential inlet connected to or proximate to the first end, atangential outlet connected to or proximate to the second end, anelectrode housing connected to the first end of the cylindrical vesselsuch that a first electrode is (a) aligned with a longitudinal axis ofthe cylindrical vessel, and (b) extends into the cylindrical vessel, ahollow electrode nozzle connected to the second end of the cylindricalvessel such that the center line of the hollow electrode nozzle isaligned with the longitudinal axis of the cylindrical vessel, andwherein the tangential inlet and the tangential outlet create a vortexwithin the cylindrical vessel, and the first electrode and the hollowelectrode nozzle create a plasma that discharges through the hollowelectrode nozzle. A first valve is connected to a wastewater source. Aneductor has a first inlet, a second inlet and an outlet, wherein thefirst inlet is connected to the outlet of the electrically conductivecylindrical vessel, the second inlet is connected to the first valve,and the outlet is connected to the tangential inlet of the plasma arctorch. A second valve is connected between the tangential outlet of theplasma arc torch and the inlet of the glow discharge cell, such that theplasma arc torch provides the electrically conductive fluid to the glowdischarge cell and the glow discharge cell provides a treated water viathe outlet centered in the closed second end.

The present invention also provides a system that includes a glowdischarge cell and a plasma arc torch. The glow discharge cell includesan electrically conductive cylindrical vessel having a first end and aclosed second end, an inlet proximate to the first end, and an outletcentered in the closed second end, a hollow electrode aligned with alongitudinal axis of the electrically conductive cylindrical vessel andextending at least from the first end into the electrically conductivecylindrical vessel, wherein the hollow electrode has an inlet and anoutlet, a first insulator that seals the first end of the electricallyconductive cylindrical vessel around the hollow electrode and maintainsa substantially equidistant gap between the electrically conductivecylindrical vessel and the hollow electrode, and a non-conductivegranular material disposed within the substantially equidistant gap,wherein the non-conductive granular material allows an electricallyconductive fluid to flow between the electrically conductive cylindricalvessel and the hollow electrode, and the combination of thenon-conductive granular material and the electrically conductive fluidprevents electrical arcing between the cylindrical vessel and the hollowelectrode during an electric glow discharge. The plasma arc torchincludes a cylindrical vessel having a first end and a second end, atangential inlet connected to or proximate to the first end, atangential outlet connected to or proximate to the second end, anelectrode housing connected to the first end of the cylindrical vesselsuch that a first electrode is (a) aligned with a longitudinal axis ofthe cylindrical vessel, and (b) extends into the cylindrical vessel, ahollow electrode nozzle connected to the second end of the cylindricalvessel such that the center line of the hollow electrode nozzle isaligned with the longitudinal axis of the cylindrical vessel, andwherein the tangential inlet and the tangential outlet create a vortexwithin the cylindrical vessel, and the first electrode and the hollowelectrode nozzle create a plasma that discharges through the hollowelectrode nozzle. A linear actuator is connected to the first electrodeof the plasma arc torch to adjust a position of the first electrodewithin the cylindrical vessel along the longitudinal axis of thecylindrical vessel. A pump is connected to a wastewater source. A firstvalve is connected to the pump. A compressed gas source is connected tothe first valve. A third valve is connected between the outlet of theelectrically conductive cylindrical vessel. An eductor has a firstinlet, a second inlet and an outlet, wherein the first inlet isconnected to the third valve, the second inlet is connected to the firstvalve, and the outlet is connected to the tangential inlet of the plasmaarc torch. A second valve is connected between the tangential outlet ofthe plasma arc torch and the inlet of the glow discharge cell, such thatthe plasma arc torch provides the electrically conductive fluid to theglow discharge cell and the glow discharge cell provides a treated watervia the outlet centered in the closed second end.

The present invention is described in detail below with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be betterunderstood by referring to the following description in conjunction withthe accompanying drawings, in which:

FIG. 1 is a diagram of a plasma arc torch in accordance with oneembodiment of the present invention;

FIG. 2 is a cross-sectional view comparing and contrasting a solid oxidecell to a liquid electrolyte cell in accordance with one embodiment ofthe present invention;

FIG. 3 is a graph showing an operating curve a glow discharge cell inaccordance with one embodiment of the present invention.

FIG. 4 is a cross-sectional view of a glow discharge cell in accordancewith one embodiment of the present invention;

FIG. 5 is a cross-sectional view of a glow discharge cell in accordancewith another embodiment of the present invention;

FIG. 6 is a cross-sectional view of a Solid Oxide Plasma Arc TorchSystem in accordance with another embodiment of the present invention;

FIG. 7 is a cross-sectional view of a Solid Oxide Plasma Arc TorchSystem in accordance with another embodiment of the present invention;

FIG. 8 is a cross-sectional view of a Solid Oxide Transferred Arc PlasmaTorch in accordance with another embodiment of the present invention;

FIG. 9 is a cross-sectional view of a Solid Oxide Non-Transferred ArcPlasma Torch in accordance with another embodiment of the presentinvention;

FIG. 10 is a table showing the results of the tailings pond water andsolids analysis treated with one embodiment of the present invention;

FIG. 11 is block diagram of a water/wastewater treatment plant inaccordance with the prior art;

FIG. 12 is block diagram of a water/wastewater treatment plant recycleand reuse system in accordance with another embodiment of the presentinvention; and

FIG. 13 is a flow diagram of representative activated sludge wastewatertreatment process sequence in accordance with the prior art.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the presentinvention are discussed in detail below, it should be appreciated thatthe present invention provides many applicable inventive concepts thatcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the invention and do not delimit the scope of theinvention.

Now referring to FIG. 1, a plasma arc torch 100 in accordance with oneembodiment of the present invention is shown. The plasma arc torch 100is a modified version of the ARCWHIRL® device disclosed in U.S. Pat. No.7,422,695 (which is hereby incorporated by reference in its entirety)that produces unexpected results. More specifically, by attaching adischarge volute 102 to the bottom of the vessel 104, closing off thevortex finder, replacing the bottom electrode with a hollow electrodenozzle 106, an electrical arc can be maintained while discharging plasma108 through the hollow electrode nozzle 106 regardless of how much gas(e.g., air), fluid (e.g., water) or steam 110 is injected into plasmaarc torch 100. In addition, when a valve (not shown) is connected to thedischarge volute 102, the mass flow of plasma 108 discharged from thehollow electrode nozzle 106 can be controlled by throttling the valve(not shown) while adjusting the position of the first electrode 112using the linear actuator 114.

As a result, plasma arc torch 100 includes a cylindrical vessel 104having a first end 116 and a second end 118. A tangential inlet 120 isconnected to or proximate to the first end 116 and a tangential outlet102 (discharge volute) is connected to or proximate to the second end118. An electrode housing 122 is connected to the first end 116 of thecylindrical vessel 104 such that a first electrode 112 is aligned withthe longitudinal axis 124 of the cylindrical vessel 104, extends intothe cylindrical vessel 104, and can be moved along the longitudinal axis124. Moreover, a linear actuator 114 is connected to the first electrode112 to adjust the position of the first electrode 112 within thecylindrical vessel 104 along the longitudinal axis of the cylindricalvessel 124 as indicated by arrows 126. The hollow electrode nozzle 106is connected to the second end 118 of the cylindrical vessel 104 suchthat the center line of the hollow electrode nozzle 106 is aligned withthe longitudinal axis 124 of the cylindrical vessel 104. The shape ofthe hollow portion 128 of the hollow electrode nozzle 106 can becylindrical or conical. Moreover, the hollow electrode nozzle 106 canextend to the second end 118 of the cylindrical vessel 104 or extendinto the cylindrical vessel 104 as shown. As shown in FIG. 1, thetangential inlet 120 is volute attached to the first end 116 of thecylindrical vessel 104, the tangential outlet 102 is a volute attachedto the second end 118 of the cylindrical vessel 104, the electrodehousing 122 is connected to the inlet volute 120, and the hollowelectrode nozzle 106 (cylindrical configuration) is connected to thedischarge volute 102. Note that the plasma arc torch 100 is not shown toscale.

A power supply 130 is electrically connected to the plasma arc torch 100such that the first electrode 112 serves as the cathode and the hollowelectrode nozzle 106 serves as the anode. The voltage, power and type ofthe power supply 130 is dependant upon the size, configuration andfunction of the plasma arc torch 100. A gas (e.g., air), fluid (e.g.,water) or steam 110 is introduced into the tangential inlet 120 to forma vortex 132 within the cylindrical vessel 104 and exit through thetangential outlet 102 as discharge 134. The vortex 132 confines theplasma 108 within in the vessel 104 by the inertia (inertial confinementas opposed to magnetic confinement) caused by the angular momentum ofthe vortex, whirling, cyclonic or swirling flow of the gas (e.g., air),fluid (e.g., water) or steam 110 around the interior of the cylindricalvessel 104. During startup, the linear actuator 114 moves the firstelectrode 112 into contact with the hollow electrode nozzle 106 and thendraws the first electrode 112 back to create an electrical arc whichforms the plasma 108 that is discharged through the hollow electrodenozzle 106. During operation, the linear actuator 114 can adjust theposition of the first electrode 112 to change the plasma 108 dischargeor account for extended use of the first electrode 112.

Referring now to FIG. 2, a cross-sectional view comparing andcontrasting a solid oxide cell 200 to a liquid electrolyte cell 250 inaccordance with one embodiment of the present invention is shown. Anexperiment was conducted using the Liquid Electrolyte Cell 250. A carboncathode 202 was connected to a linear actuator 204 in order to raise andlower the cathode 202 into a carbon anode crucible 206. An ESAB ESP 150DC power supply rated at 150 amps and an open circuit voltage (“OCV”) of370 VDC was used for the test. The power supply was “tricked out” inorder to operate at OCV.

In order to determine the sheath glow discharge length on the cathode202 as well as measure amps and volts the power supply was turned on andthen the linear actuator 204 was used to lower the cathode 202 into anelectrolyte solution of water and baking soda. Although a steady glowdischarge could be obtained the voltage and amps were too erratic torecord. Likewise, the power supply constantly surged and pulsed due toerratic current flow. As soon as the cathode 202 was lowered too deep,the glow discharge ceased and the cell went into an electrolysis mode.In addition, since boiling would occur quite rapidly and the electrolytewould foam up and go over the sides of the carbon crucible 206, foundrysand was added reduce the foam in the crucible 206.

The 8″ diameter anode crucible 206 was filled with sand and theelectrolyte was added to the crucible. Power was turned on and thecathode 202 was lowered into the sand and electrolyte. Unexpectedly, aglow discharge was formed immediately, but this time it appeared tospread out laterally from the cathode 202. A large amount of steam wasproduced such that it could not be seen how far the glow discharge hadextended through the sand.

Next, the sand was replaced with commonly available clear floralmarbles. When the cathode 202 was lowered into the marbles and bakingsoda/water solution, the electrolyte began to slowly boil. As soon asthe electrolyte began to boil a glow discharge spider web could be seenthroughout the marbles as shown the Solid Oxide Cell 200. Although thiswas completely unexpected at a much lower voltage than what has beendisclosed and published, what was completely unexpected is that the DCpower supply did not surge, pulse or operate erratically in any way. Agraph showing an operating curve for a glow discharge cell in accordancewith the present invention is shown in FIG. 3 based on various tests.The data is completely different from what is currently published withrespect to glow discharge graphs and curves developed from currentlyknown electro-plasma, plasma electrolysis or glow discharge reactors.Glow discharge cells can evaporate or concentrate liquids whilegenerating steam.

Now referring to FIG. 4, a cross-sectional view of a glow discharge cell400 in accordance with one embodiment of the present invention is shown.The glow discharge cell 400 includes an electrically conductivecylindrical vessel 402 having a first end 404 and a second end 406, andat least one inlet 408 and one outlet 410. A hollow electrode 412 isaligned with a longitudinal axis of the cylindrical vessel 402 andextends at least from the first end 404 to the second end 406 of thecylindrical vessel 402. The hollow electrode 412 also has an inlet 414and an outlet 416. A first insulator 418 seals the first end 404 of thecylindrical vessel 402 around the hollow electrode 412 and maintains asubstantially equidistant gap 420 between the cylindrical vessel 402 andthe hollow electrode 412. A second insulator 422 seals the second end406 of the cylindrical vessel 402 around the hollow electrode 412 andmaintains the substantially equidistant gap 420 between the cylindricalvessel 402 and the hollow electrode 412. A non-conductive granularmaterial 424 is disposed within the gap 420, wherein the non-conductivegranular material 424 (a) allows an electrically conductive fluid toflow between the cylindrical vessel 402 and the hollow electrode 412,and (b) prevents electrical arcing between the cylindrical vessel 402and the hollow electrode 412 during a electric glow discharge. Theelectric glow discharge is created whenever: (a) the glow discharge cell400 is connected to an electrical power source such that the cylindricalvessel 402 is an anode and the hollow electrode 412 is a cathode, and(b) the electrically conductive fluid is introduced into the gap 420.

The vessel 402 can be made of stainless steel and the hollow electrodecan be made of carbon. The non-conductive granular material 424 can bemarbles, ceramic beads, molecular sieve media, sand, limestone,activated carbon, zeolite, zirconium, alumina, rock salt, nut shell orwood chips. The electrical power supply can operate in a range from 50to 500 volts DC, or a range of 200 to 400 volts DC. The cathode 412 canreach a temperature of at least 500° C., at least 1000° C., or at least2000° C. during the electric glow discharge. The electrically conductivefluid comprises water, produced water, wastewater, tailings pond water,or other suitable fluid. The electrically conductive fluid can becreated by adding an electrolyte, such as baking soda, Nahcolite, lime,sodium chloride, ammonium sulfate, sodium sulfate or carbonic acid, to afluid.

Referring now to FIG. 5, a cross-sectional view of a glow discharge cell500 in accordance with another embodiment of the present invention isshown. The glow discharge cell 500 includes an electrically conductivecylindrical vessel 402 having a first end 404 and a closed second end502, an inlet proximate 408 to the first end 404, and an outlet 410centered in the closed second end 502. A hollow electrode 504 is alignedwith a longitudinal axis of the cylindrical vessel and extends at leastfrom the first end 404 into the cylindrical vessel 402. The hollowelectrode 504 has an inlet 414 and an outlet 416. A first insulator 418seals the first end 404 of the cylindrical vessel 402 around the hollowelectrode 504 and maintains a substantially equidistant gap 420 betweenthe cylindrical vessel 402 and the hollow electrode 504. Anon-conductive granular material 424 is disposed within the gap 420,wherein the non-conductive granular material 424 (a) allows anelectrically conductive fluid to flow between the cylindrical vessel 402and the hollow electrode 504, and (b) prevents electrical arcing betweenthe cylindrical vessel 402 and the hollow electrode 504 during aelectric glow discharge. The electric glow discharge is createdwhenever: (a) the glow discharge cell 500 is connected to an electricalpower source such that the cylindrical vessel 402 is an anode and thehollow electrode 504 is a cathode, and (b) the electrically conductivefluid is introduced into the gap 420.

The following examples will demonstrate the capabilities, usefulness andcompletely unobvious and unexpected results.

Example 1 Black Liquor

Now referring to FIG. 6, a cross-sectional view of a Solid Oxide PlasmaArc Torch System 600 in accordance with another embodiment of thepresent invention is shown. A plasma arc torch 100 is connected to thecell 500 via an eductor 602. Once again the cell 500 was filled with abaking soda and water solution. A pump was connected to the first volute31 of the plasma arc torch 100 via a 3-way valve 604 and the eductor602. The eductor 602 pulled a vacuum on the cell 500. The plasma exitingfrom the plasma arc torch 100 dramatically increased in size. Hence, anon-condensable gas B was produced within the cell 500. The color of thearc within the plasma arc torch 100 when viewed through the sightglass33 changed colors due to the gases produced from the HiTemper™ cell 500.Next, the 3-way valve 604 was adjusted to allow air and water F to flowinto the first volute 31 of plasma arc torch 100. The additional massflow increased the plasma G exiting from the plasma arc torch 100.Several pieces of stainless steel round bar were placed at the tip ofthe plasma G and melted to demonstrate the systems capabilities.Likewise, wood was carbonized by placing it within the plasma stream G.Thereafter the plasma G exiting from the plasma torch 100 was directedinto cyclone separator 610. The water and gases I exiting from theplasma arc torch 100 via second volute 34 flowed into a hydrocyclone 608via a valve 606. This allowed for rapid mixing and scrubbing of gaseswith the water in order to reduce the discharge of any hazardouscontaminants.

A sample of black liquor with 16% solids obtained from a pulp and papermill was charged to the glow discharge cell 500 in a sufficient volumeto cover the floral marbles 424. In contrast to other glow discharge orelectro plasma systems the solid oxide glow discharge cell does notrequire preheating of the electrolyte. The ESAB ESP 150 power supply wasturned on and the volts and amps were recorded by hand. Referringbriefly to FIG. 3, as soon as the power was turned on to the cell 500,the amp meter pegged out at 150. Hence, the name of the ESAB powersupply—ESP 150. It is rated at 150 amps. The voltage was steady between90 and 100 VDC. As soon as boiling occurred the voltage steadily climbedto OCV (370 VDC) while the amps dropped to 75.

The glow discharge cell 500 was operated until the amps fell almost tozero. Even at very low amps of less than 10 the voltage appeared to belocked on at 370 VDC. The cell 500 was allowed to cool and then openedto examine the marbles 424. It was surprising that there was no visibleliquid left in the cell 500 but all of the marbles 424 were coated orcoked with a black residue. The marbles 424 with the black residue wereshipped off for analysis. The residue was in the bottom of the containerand had come off of the marbles 424 during shipping. The analysis islisted in the table below, which demonstrates a novel method forconcentrating black liquor and coking organics. With a starting solidsconcentration of 16%, the solids were concentrated to 94.26% with onlyone evaporation step. Note that the sulfur (“S”) stayed in the residueand did not exit the cell 500.

-   -   Total Solids % 94.26    -   Ash %/ODS 83.64    -   ICP metal scan: results are reported on ODS basis

TABLE Black Liquor Results Metal Scan Unit F80015 Aluminum, Al mg/kg3590*  Arsenic, As mg/kg <50  Barium, Ba mg/kg 2240*  Boron, B mg/kg 60Cadmium, Cd mg/kg  2 Calcium, Ca mg/kg 29100*  Chromium, Cr mg/kg 31Cobalt, Co mg/kg <5 Copper, Cu mg/kg 19 Iron, Fe mg/kg 686* Lead, Pbmg/kg <20  Lithium, Li mg/kg 10 Magnesium, Mg mg/kg 1710*  Manganese, Mnmg/kg   46.2 Molybdenum, Mo mg/kg 40 Nickel, Ni mg/kg <100  Phosphorus,P mg/kg 35 Potassium, K mg/kg 7890  Silicon, Si mg/kg 157000*   Sodium,Na mg/kg 102000   Strontium, Sr mg/kg <20  Sulfur, S mg/kg 27200* Titanium, Ti mg/kg  4 Vanadium, V mg/kg   1.7 Zinc, Zn mg/kg 20This method can be used for concentrating black liquor from pulp, paperand fiber mills for subsequent recaustizing.

As can be seen in FIG. 3, if all of the liquid evaporates from the cell500 and it is operated only with a solid electrolyte, electrical arcover from the cathode to anode may occur. This has been tested in whichcase a hole was blown through the stainless steel vessel 402. Electricalarc over can easily be prevented by (1) monitoring the liquid level inthe cell and do not allow it to run dry, and (2) monitoring the amps(Low amps=Low liquid level). If electrical arc over is desirable or thecell must be designed to take an arc over, then the vessel 402 should beconstructed of carbon.

Example 2 Arcwhirl® Plasma Torch Attached to Solid Oxide Cell

Referring now to FIG. 7, a cross-sectional view of a Solid Oxide PlasmaArc Torch System 700 in accordance with another embodiment of thepresent invention is shown. A plasma arc torch 100 is connected to thecell 500 via an eductor 602. Once again the cell 500 was filled with abaking soda and water solution. Pump 23 recirculates the baking soda andwater solution from the outlet 416 of the hollow electrode 504 to theinlet 408 of the cell 500. A pump 22 was connected to the first volute31 of the plasma arc torch 100 via a 3-way valve 604 and the eductor602. An air compressor 21 was used to introduce air into the 3-way valve604 along with water F from the pump 22. The pump 22 was turned on andwater F flowed into the first volute 31 of the plasma arc torch 100 andthrough a full view site glass 33 and exited the torch 30 via a secondvolute 34. The plasma arc torch 100 was started by pushing a carboncathode rod (−NEG) 32 to touch and dead short to a positive carbon anode(+POS) 35. A very small plasma G exited out of the anode 35. Next, theHigh Temperature Plasma Electrolysis Reactor (Cell) 500 was started inorder to produce a plasma gas B. Once again at the onset of boilingvoltage climbed to OCV (370 VDC) and a gas began flowing to the plasmaarc torch 100. The eductor 602 pulled a vacuum on the cell 500. Theplasma G exiting from the plasma arc torch 100 dramatically increased insize. Hence, a non-condensable gas B was produced within the cell 500.The color of the arc within the plasma arc torch 100 when viewed throughthe sightglass 33 changed colors due to the gases produced from theHiTemper™ cell 500. Next, the 3-way valve 604 was adjusted to allow airfrom compressor 21 and water from pump 22 to flow into the plasma arctorch 100. The additional mass flow increased the plasma G exiting fromthe plasma arc torch 100. Several pieces of stainless steel round barwere placed at the tip of the plasma G and melted to demonstrate thesystems capabilities. Likewise, wood was carbonized by placing it withinthe plasma stream G. The water and gases exiting from the plasma arctorch 100 via volute 34 flowed into a hydrocyclone 608. This allowed forrapid mixing and scrubbing of gases with the water in order to reducethe discharge of any hazardous contaminants.

Next, the system was shut down and a second cyclone separator 610 wasattached to the plasma arc torch 100 as shown in FIG. 5. Once again theSolid Oxide Plasma Arc Torch System was turned on and a plasma G couldbe seen circulating within the cyclone separator 610. Within the eye orvortex of the whirling plasma G was a central core devoid of any visibleplasma.

The cyclone separator 610 was removed to conduct another test. Todetermine the capabilities of the Solid Oxide Plasma Arc Torch System asshown in FIG. 6, the pump 22 was turned off and the system was operatedonly on air provided by compressor 21 and gases B produced from thesolid oxide cell 500. Next, 3-way valve 606 was slowly closed in orderto force all of the gases through the arc to form a large plasma Gexiting from the hollow carbon anode 35.

Next, the 3-way valve 604 was slowly closed to shut the flow of air tothe plasma arc torch 100. What happened was completely unexpected. Theintensity of the light from the sightglass 33 increased dramatically anda brilliant plasma was discharged from the plasma arc torch 100. Whenviewed with a welding shield the arc was blown out of the plasma arctorch 100 and wrapped back around to the anode 35. Thus, the Solid OxidePlasma Arc Torch System will produce a gas and a plasma suitable forwelding, melting, cutting, spraying and chemical reactions such aspyrolysis, gasification and water gas shift reaction.

Example 3 Phosphogypsum Pond Water

The phosphate industry has truly left a legacy in Florida, Louisiana andTexas that will take years to cleanup—gypsum stacks and pond water. Ontop of every stack is a pond. Pond water is recirculated from the pondback down to the plant and slurried with gypsum to go up the stack andallow the gypsum to settle out in the pond. This cycle continues and thegypsum stack increases in height. The gypsum is produced as a byproductfrom the ore extraction process.

There are two major environmental issues with every gyp stack. First,the pond water has a very low pH. It cannot be discharged withoutneutralization. Second, the phosphogypsum contains a slight amount ofradon. Thus, it cannot be used or recycled to other industries. Theexcess water in combination with ammonia contamination produced duringthe production of P₂O₅ fertilizers such as diammonium phosphate (“DAP”)and monammonium phosphate (“MAP”) must be treated prior to discharge.The excess pond water contains about 2% phosphate a valuable commodity.

A sample of pond water was obtained from a Houston phosphate fertilizercompany. The pond water was charged to the solid oxide cell 500. TheSolid Oxide Plasma Arc Torch System was configured as shown in FIG. 6.The 3-way valve 606 was adjusted to flow only air into the plasma arctorch 100 while pulling a vacuum on cell 500 via eductor 602. The hollowanode 35 was blocked in order to maximize the flow of gases I tohydrocyclone 608 that had a closed bottom with a small collectionvessel. The hydrocyclone 608 was immersed in a tank in order to cool andrecover condensable gases.

The results are disclosed in FIG. 10—Tailings Pond Water Results. Thegoal of the test was to demonstrate that the Solid Oxide Glow DischargeCell could concentrate up the tailings pond water. Turning now to cyclesof concentration, the percent P₂O₅ was concentrated up by a factor of 4for a final concentration of 8.72% in the bottom of the HiTemper™ cell500. The beginning sample as shown in the picture is a colorless,slightly cloudy liquid. The bottoms or concentrate recovered from theHiTemper cell 500 was a dark green liquid with sediment. The sedimentwas filtered and are reported as SOLIDS (Retained on Whatmann #40 filterpaper). The percent SO₄ recovered as a solid increased from 3.35% to13.6% for a cycles of concentration of 4. However, the percent Narecovered as a solid increased from 0.44% to 13.67% for a cycles ofconcentration of 31.

The solid oxide or solid electrolyte 424 used in the cell 500 werefloral marbles (Sodium Oxide). Floral marbles are made of sodium glass.Not being bound by theory it is believed that the marbles were partiallydissolved by the phosphoric acid in combination with the hightemperature glow discharge. Chromate and Molydemun cycled up andremained in solution due to forming a sacrificial anode from thestainless steel vessel 402. Note: Due to the short height of the cellcarryover occurred due to pulling a vacuum on the cell 500 with eductor602. In the first run (row 1 HiTemper) of FIG. 10 very little fluorinewent overhead. That had been a concern from the beginning that fluorinewould go over head. Likewise about 38% of the ammonia went overhead. Itwas believed that all of the ammonia would flash and go overhead.

A method has been disclosed for concentrating P₂O₅ from tailings pondfor subsequent recovery as a valuable commodity acid and fertilizer.

Now, returning back to the black liquor sample, not being bound bytheory it is believed that the black liquor can be recaustisized bysimply using CaO or limestone as the solid oxide electrolyte 424 withinthe cell 500. Those who are skilled in the art of producing pulp andpaper will truly understand the benefits and cost savings of not havingto run a lime kiln. However, if the concentrated black liquor must begasified or thermally oxidized to remove all carbon species, the marbles424 can be treated with the plasma arc torch 100. Referring back to FIG.6, the marbles 424 coated with the concentrated black liquor or theconcentrated black liquor only is injected between the plasma arc torch100 and the cyclone separator 610. This will convert the black liquorinto a green liquor or maybe a white liquor. The marbles 424 may beflowed into the plasma arc torch nozzle 31 and quenched in the whirlinglime water and discharged via volute 34 into hydrocyclone 608 forseparation and recovery of both white liquor and the marbles 424. Thelime will react with the NaO to form caustic and an insoluble calciumcarbonate precipitate.

Example 4 Evaporation, Vapor Compression and Steam Generation for EORand Industrial Steam Users

Turning to FIG. 4, several oilfield wastewaters were evaporated in thecell 400. In order to enhance evaporation the suction side of a vaporcompressor (not shown) can be connected to upper outlet 410. Thedischarge of the vapor compressor would be connected to 416. Not beingbound by theory, it is believed that alloys such as Kanthal®manufactured by the Kanthal® corporation may survive the intense effectsof the cell as a tubular cathode 412, thus allowing for a novel steamgenerator with a superheater by flowing the discharge of the vaporcompressor through the tubular cathode 412. Such an apparatus, methodand process would be widely used throughout the upstream oil and gasindustry in order to treat oilfield produced water and frac flowback.

Several different stainless steel tubulars were tested within the cell500 as the cathode 12. In comparison to the sheath glow discharge thetubulars did not melt. In fact, when the tubulars were pulled out, amarking was noticed at every point a marble was in contact with thetube.

This gives rise to a completely new method for using glow discharge totreat metals.

Example 5 Treating Tubes, Bars, Rods, Pipe or Wire

There are many different companies applying glow discharge to treatmetal. However, many have companies have failed miserably due to arcingover and melting the material to be coated, treated or descaled. Theproblem with not being able to control voltage leads to spikes. Bysimply adding sand or any solid oxide to the cell and feeding the tubecathode 12 through the cell 500 as configured in FIG. 2, the tube, rod,pipe, bars or wire can be treated at a very high feedrate.

Example 6 Solid Oxide Plasma Arc Torch

There truly exists a need for a very simple plasma torch that can beoperated with dirty or highly polluted water such as sewage flusheddirectly from a toilet which may contain toilet paper, feminine napkins,fecal matter, pathogens, urine and pharmaceuticals. A plasma torchsystem that could operate on the aforementioned waters could potentiallydramatically affect the wastewater infrastructure and future costs ofmaintaining collection systems, lift stations and wastewater treatmentfacilities.

By converting the contaminated wastewater to a gas and using the gas asa plasma gas could also alleviate several other growingconcerns—municipal solid waste going to landfills, grass clippings andtree trimmings, medical waste, chemical waste, refinery tank bottoms,oilfield wastes such as drill cuttings and typical everyday householdgarbage. A simple torch system which could handle both solid waste andliquids or that could heat a process fluid while gasifying biomass orcoal or that could use a wastewater to produce a plasma cutting gaswould change many industries overnight.

One industry in particular is the metals industry. The metals industryrequires a tremendous amount of energy and exotic gases for heating,melting, welding, cutting and machining.

Turning now to FIGS. 8 and 9, a truly novel plasma torch 800 will bedisclosed in accordance with the preferred embodiments of the presentinvention. First, the Solid Oxide Plasma Torch is constructed bycoupling the plasma arc torch 100 to the cell 500. The plasma arc torchvolute 31 and electrode 32 are detached from the eductor 602 andsightglass 33. The plasma arc torch volute 31 and electrode assembly 32are attached to the cell 500 vessel 402. The sightglass 33 is replacedwith a concentric type reducer 33. It is understood that the electrode32 is electrically isolated from the volute 31 and vessel 402. Theelectrode 32 is connected to a linear actuator (not shown) in order tostrike the arc.

Continuous Operation of the Solid Oxide Transferred Arc Plasma Torch 800as shown in FIG. 8 will now be disclosed for cutting or melting anelectrically conductive workpiece. A fluid is flowed into the suctionside of the pump and into the cell 500. The pump is stopped. A firstpower supply PS1 is turned on thus energizing the cell 500. As soon asthe cell 500 goes into glow discharge and a gas is produced valve 16opens allowing the gas to enter into the volute 31. The volute 31imparts a whirl flow to the gas. A switch 60 is positioned such that asecond power supply PS2 is connected to the workpiece and the −negativeside of PS2 is connected to the −negative of PS1 which is connected tothe centered cathode 504 of the cell 500. The entire torch is lowered sothat an electrically conductive nozzle 13-C touches and is grounded tothe workpiece. PS2 is now energized and the torch is raised from theworkpiece. An arc is formed between cathode 504 and the workpiece.

Centering the Arc—If the arc must be centered for cutting purposes, thenPS2's—negative lead would be attached to the lead of switch 60 that goesto the electrode 32. Although a series of switches are not shown forthis operation, it will be understood that in lieu of manually switchingthe negative lead from PS2 an electrical switch similar to 60 could beused for automation purposes. The +positive lead would simply go to theworkpiece as shown. A smaller electrode 32 would be used such that itcould slide into and through the hollow cathode 504 in order to touchthe workpiece and strike an arc. The electrically conductive nozzle 802would be replaced with a non-conducting shield nozzle. This setup allowsfor precision cutting using just wastewater and no other gases.

Turning to FIG. 9, the Solid Oxide Non-Transferred Arc Plasma Torch 800is used primarily for melting, gasifying and heating materials whileusing a contaminated fluid as the plasma gas. Switch 60 is adjusted suchthat PS2+lead feeds electrode 32. Once again electrode 32 is nowoperated as the anode. It must be electrically isolated from vessel 402.When gas begins to flow by opening valve 16 the volute 31 imparts a spinor whirl flow to the gas. The anode 32 is lowered to touch the centeredcathode 504. An arc is formed between the cathode 32 and anode 504. Theanode may be hollow and a wire may be fed through the anode 504 forplasma spraying, welding or initiating the arc.

The entire torch is regeneratively cooled with its own gases thusenhancing efficiency. Likewise, a waste fluid is used as the plasma gaswhich reduces disposal and treatment costs. Finally, the plasma may beused for gasifying coal, biomass or producing copious amounts of syngasby steam reforming natural gas with the hydrogen and steam plasma.

Both FIGS. 8 and 9 have clearly demonstrated a novel Solid Oxide PlasmaArc Torch that couples the efficiencies of high temperature electrolysiswith the capabilities of both transferred and non-transferred arc plasmatorches.

Example 7 Water/Wastewater Treatment

Chemicals are being discovered in water that previously had not beendetected or are being detected at levels that may be significantlydifferent than expected. These are often generally referred to as“contaminants of emerging concern” (CECs) because the risk to humanhealth and the environment associated with their presence, frequency ofoccurrence, or source may not be known. U.S. Environmental ProtectionAgency (“EPA”) is working to improve its understanding of a number ofCECs, particularly pharmaceuticals and personal care products (PPCPs)and perfluorinated compounds among others. Pharmaceuticals refer toprescription and over-the-counter therapeutic drugs and veterinarydrugs. Personal care products refer to products used for personal andcosmetic reasons such as soaps, fragrances, and cosmetics.

The last decade has seen increased documentation of trace concentrations(low parts-per-trillion) levels of PPCPs in surface water, groundwater,and finished drinking water. While PPCPs can originate from numeroussources, effluents from wastewater treatment plants (WWTPs) have beenidentified as a significant source to surface waters. PPCPs can enterWWTPs when people excrete pharmaceutical products or their metabolites,or flush unused medications down a drain or sewer system. Thepharmaceutical drugs that have been detected nationally comprise a largerange of emerging drinking water contaminants, including prescriptionand over-the-counter drugs, antibiotics, tranquilizers, antidepressants,and other organic chemicals. The personal care products that have beendetected include but are not limited to: fragrances, disinfectants,sunscreen, preservatives, and surfactants or their metabolites. See:2010 Occurrence of Pharmaceutical and Personal Care Products (PPCPs) inSource Water of the New York City WaterSupply—http://www.nyc.gov/html/dep/pdf/quality/nyc_dep_2010_ppcpreport.pdf;and Kolpin D W, Furlong E T, Meyer M T, Thurman E M, Zaugg S D, Barber LB, et al. 2002.—Pharmaceuticals, hormones, and other organic wastewatercontaminants in U.S. streams, 1999-2000: a national reconnaissance.Environmental Science and Technology 36(6): 1202-11.

The EPA defines PPCPs as pollutants in general, to any product used byindividuals for personal health or cosmetic reasons or used byagribusiness to enhance growth or health of livestock. PPCPs comprise adiverse collection of thousands of chemical substances, includingprescription and over-the-counter therapeutic drugs, veterinary drugs,fragrances, and cosmetics. Research suggests that certain drugs maycause ecological harm. PPCPs have probably been present in water and theenvironment for as long as humans have been using them. The drugs thatwe take are not entirely absorbed by our bodies, and are excreted andpassed into wastewater and surface water. With advances in technologythat improved the ability to detect and quantify these chemicals, we cannow begin to identify what effects, if any, these chemicals have onhuman and environmental health. The number of PPCPs is growing. Inaddition to antibiotics and steroids, over 100 individual PPCPs havebeen identified (as of 2007) in environmental samples and drinkingwater. The EPA has stated that sewage systems are not equipped for PPCPremoval and that there are no municipal sewage treatment plants that areengineered specifically for PPCP removal or for other unregulatedcontaminants. Effective removal of PPCPs from treatment plants variesbased on the type of chemical and on the individual sewage treatmentfacilities.

Referring to FIG. 11, a typical activated sludge wastewater treatmentplant is shown that will not remove PPCPs and effluent is not suitablefor recycling and reuse. Turning now to FIG. 12 while referring to FIGS.1, 4, 5, 6 and 7, and specifically units 100, 400, 500, 600 and 700, awastewater treatment plant can be modified and retrofitted for treatingemerging contaminants and or polishing wastewater for reuse.

First, waste water influent may be pretreated by installation of eitherunit 400 or 500 as shown in FIGS. 4 and 5 respectively. Activated carbonas previously disclosed would be the ideal filtration media for the glowdischarge cell. Units 400 and 500 are operated as normal activatedcarbon filters until the carbon is spent.

The activated carbon can be regenerated with the glow discharge plasmacell. Consequently, by using two or more filters, one can be onlinewhile the other is being reactivated. To reactive the carbon the powersupply is turned ON, and the carbon is allowed to heat up and generatesteam in situ from the remaining wastewater or by adding an electrolyte.The electrolyte may be chosen from any of the aforementionedelectrolytes and specifically, phosphoric acid may be generated fromanother glow discharge cell and used for reactivating carbon in additionto steam. The present invention allows for onsite reactivation of spentactivated carbon. Furthermore as previously disclosed, the presentinvention's glow discharge cell will produce steam and hydrogen forflowing to Plasma ArcWhirl® Torch 100 as shown in FIGS. 6 and 7 for useas a plasma gas.

While still referring to FIG. 12 wastewater may be polished for removalof PPCPs by installation of Unit 700 as shown in FIG. 7. Turning now toFIG. 7 wastewater F is flowed into the Plasma ArcWhirl® Torch 100 via a3-way mixing valve 604 and may used as the motive fluid in eductor 602.A Gas flows into 3-way valve 17 and into a compressor 21. Compressed gasis then flowed into the 3-way mixing valve 604.

As previously disclosed a thin film of whirling water is created byintroduction of the gas with the water into the Plasma ArcWhirl® 100.The water is exposed directly to an intense source of ElectroMagneticRadiation (“EMR”) emitted from both the plasma and the carbon electrode.In addition, ozone is generated from the electrical arc and is partiallymixed with the water when exiting via volute 34. Likewise, since thesystem is grounded if there is sufficient electrical conductivity in thewater, then the water may be treated via electrolysis also.

Turning now to FIG. 1, a unique and extremely novel regenerativelycooled plasma torch will be demonstrated for treating water while alsogenerating Char via Plasma 108. A combination of a Gas and a Fluid(Water) 110 is flowed into the Plasma ArcWhirl® Torch 100 in order tomaintain a gas only discharge from the hollow electrode nozzle. When theunit is turned ON a Plasma 108 discharges from the hollow electrodenozzle 106. The ArcWhirl® is cooled by the water whirling within thevessel 104. Hence, the ArcWhirl® Torch 100 is regeneratively cooled withthe water it is treating via EMR, Ozone and electrolysis while alsoproducing an extremely hot plasma discharge. The hot plasma discharge isused to convert carbonaceous matter to Char and syngas.

Turning now to FIG. 6, the system would be arranged such that the plasmadischarges into a cyclone separator 610 and Biomass or hydrocarbonfeedstock is fed between the ArcWhirl® Torch 100 and the CycloneSeparator 610. Char is discharged thru the underflow of the cycloneseparator 610 while hot syngas exits the overflow of the cycloneseparator 610. If biomass is used, then it is referred to as BioChar. Bytreating the BioChar with the plasma at extreme temperatures it isconverted to activated Plasma BioChar™.

Once again the Plasma Activated BioChar™ would be used as the mediawithin the glow discharge cell as shown in FIG. 4 or 5. Now returning toFIG. 7, wastewater exits from the ArcWhirl® Torch 100 via volute 34 andthru 3-way valve 606 and is flowed into the glow discharge cell 500 asshown by line AA. The Glow Discharge Cell may be configured as shown ineither FIG. 4 or 5. Ozonated wastewater is then filtered through thePlasma Activated BioChar media and is discharged as shown by C. A novelwater treatment system has been disclosed that couples Plasma Arc WaterTreatment utilizing EMR and Ozone in addition to activated carbon.

It will be understood that many drinking water and wastewater treatmentplants that operated 24/7 would incorporate at least two completesystems as shown in FIGS. 6 and 7 and/or modifications thereof forredundancy as well as allowing reactivation of spent carbon. If threeare more Plasma ArcWhirl® Torches are tangentially aligned to dischargeinto a common vessel, then this configuration would make an idealPlasmaWhirl® Reactor as disclosed in FIG. 1 of U.S. Pat. No. 7,622,693which is hereby incorporated by reference in its entirety.

Energy Generation and Recovery for the WATER-ENERGY NEXUS

Water and wastewater treatment plants could be operated off-the-grid byconverting carbonaceous matter into syngas and char with the presentinvention. This transformational approach could be responsible forsaving as much as 4% of the total electrical power generated within theUS.

As previously disclosed wood has been carbonized with the PlasmaArcWhirl® Torch 100 using a plasma gas generated from the Glow DischargeCell 500 configured as shown in FIG. 7. In addition, recent testing hasshown that the gases exiting from the Plasma ArcWhirl® Torch 100 usingbaking soda within the Glow Discharge Cell 500 as the plasma gasproduced a plasma G temperature of 2,900° C. (5,250° F.) as measuredwith an optical pyrometer. Likewise, sawdust was flowed directly intothe steam/hydrogen plasma G and were formed producing syngas with acomposition shown in the following SYNGAS TABLE:

Sample 1 Sample 2 Sample 3 Component Concentration % Concentration %Concentration % H₂ 38.702591 23.993687 31.965783 O₂ 7.603821 3.7772385.671720 N₂ 5.730443 4.424545 4.803373 CH₄ 1.042843 3.770582 2.923456 CO9.465042 14.879737 10.633168 CO₂ 30.015818 33.110154 32.207613 H₂/CO4.08/1 1.61/1 3.01/1

The syngas produced from the present invention is now ready for leancombustion with the Plasma ArcWhirl® Turbine as disclosed in U.S. Pat.No. 8,074,439. Likewise, it will be understood that the syngas can beconverted to liquid biofuels using a Fischer Tropschs catalyst or anysuitable process and/or catalyst that will convert syngas to liquidfuels.

Syngas and/or a hot gas and char are produced from the Plasma ArcWhirl®Torch's plasma plume G. The hot syngas and/or hot gas is used to rotatea turbine that is connected to a compressor, pump, generator and/ormixer. Referring to U.S. Pat. No. 8,074,439 the Plasma ArcWhirl® Turbine'439 may be operated in a lean combustion mode to simply drive aturbocharger for providing compressed air for aeration purposes.

Integrally Geared Centrifugal Compressors and High Speed Turbo Blowers

Turning now to FIG. 13, a 10 million gallons/day (“MGD”) facility isshown with daily electricity consumption. Diffused Air Aeration shows5,320 kwh/day as the largest consumer of electricity. It is well knownthat the largest energy user within an activated sludge wastewater plantis aeration. Many WWTP's are replacing aging blowers with more efficientIntegrally Geared Centrifugal Compressors and/or High Speed TurboBlowers. Integrally Geared Centrifugal Blowers and High Speed Turbos are70% to 80% efficient and have turn downs of 45% to 50%. High speedgearless turbos currently being applied within the Wastewater Industryare basically nothing more than standard vehicle and off roadturbochargers modified with a high speed motor.

The present invention's Plasma ArcWhirl® Turbine is an alternative tothese blowers. In addition, present invention also provides UVdisinfection. As explained in U.S. Pat. No. 7,422,695 which is herebyincorporated by reference in its entirety, there are several majordrawbacks to utilizing current UV light disinfection systems. All of thevarious embodiments of the ArcWhirl® devices can be modified to blow aplasma out of an electrode nozzle.

The present invention's Plasma ArcWhirl® Torch 100 as shown in FIGS. 1,5, 6, 7, 8 and 9 are completely game changing and transformational forthe wastewater industry for many reasons. However, in comparing andcontrasting the operational and life cycle costs to traditional UV lightsystem, well there isn't really much of a comparison. The twotechnologies differ dramatically, in that the Plasma ArcWhirl® Torchdoes not contain any glass nor any mercury. Thus, from a sustainabletechnology point of view there is NO comparison. From a lifecycle cost,there is no disposal of lamps, since the technology uses consumablegraphite electrodes. Keeping in mind that graphite electrodes are madefrom carbon, in particularly pet coke, any carbon material can betransformed into a graphite electrode. However, since coke is a FUEL,then the costs of the electrode is offset by its fuel value.

Returning now to FIG. 12 of the present invention, the Plasma ArcWhirl®Turbine is installed and shown by a dotted line. It replaces awastewater treatment plants blower with either a turbocharger as shownin FIG. 6—Thermal Oxidizer—of the '439 patent or as an integrally gearedsuperturbocharger as disclosed in FIG. 3, 4 or 5 for conversion torotational energy. This configuration can disinfect wastewater whilegasifying biosolids and biogas for lean combustion. Referring to FIG. 2,inlet 202C of '439 patent can be used as an entry for biosolids and anyother type of carbonaceous matter.

By coupling four systems of the present invention as shown in FIG. 6 or7 with the plasma plume G blowing into a ceramic lined vessel, a worldclass size BioChar and water treatment system can easily be configuredas a PlasmaWhirl® Reactor as shown in the FIG. 1 of the '693 patent anddisclosed as FIG. 14 of the present invention. Thus, by constructingeach ArcWhirl® to flow 1,800 gpm this equals to 10 MGD, in which FIG. 13discloses that about 5,320 kw-hr are required per day for a 10 MGDfacility for aeration purposes alone. This equates to about 221 kw-hr.2000 lbs/hour of biomass will produce about 1 MW-hr of electricity.Consequently, the present invention demonstrates a net power output bydriving a high speed gearless turbo connected to a motor generator or anintegrally geared turbine and compressor connected to a motor generator.

In a smaller version rated at 35 kw but operated at only 9 kw-hr,woodchips were converted to Plasma BioChar® by operating the presentinvention coupled to the '439 patent Thermal Oxidizer of FIG. 6. Thus,by simply using the Plasma Plume of 100 to gasify woodchips, the carbonin the wood is sequestered as a usable form of BioChar for watertreatment. The off-gas temperature was measured at over 900° C. anddumped directly into a recirculating water bath. The total processdemonstrated that for every 1 kw of out of the wall power, 2 kw of powercould be recovered within the water as hot water. Thus, this clearlydemonstrates that the present invention is capable of providingaeration, UV, Ozone, and thermal disinfection of water with reducedelectrical loading plus the production of Biochar in one system.Furthermore, the production of BioChar is a means for sequesteringcarbon.

The Biochar produced from the present invention was visually analyzedand determined to be a suitable BioChar for water treatment purposes.Consequently, as previously disclosed the Plasma BioChar™ could be usedas the media for the glow discharge cell as shown in FIGS. 4 and 5 ofthe present invention. This now closes the loop for providing atransformational and completely novel water treatment system thatproduces and reactivates its own carbon while providing rotationalenergy, UV light, Ozone and hot gases.

Finally, the present invention provides a method for UV disinfection,ozone disinfection, thermal mixing, Char production, activated carbonreactivation and supersonic lean fuel combustion by creating an electricarc, generating a water and gas whirl flow to confine a plasma from theelectric arc, generating a combustion air whirl flow, extracting arotational energy from one or more hot gases, recuperating energy fromthe hot gases, and utilizing the electrical arc for water treatmentwhile converting carbonaceous matter to Char and syngas while confiningthe plasma to the vortex of the whirling combustion air in order tomaintain and hold a flame for supersonic combustion while coupled to ameans for extracting rotational energy from the hot lean combustionexhaust gas while directly recuperating mixing energy by discharge ofthe hot exhaust from a turbine into wastewater influent while flowingdisinfected water into an activated carbon glow discharge filter forwater reuse and recycle.

The foregoing description of the apparatus and methods of the inventionin preferred and alternative embodiments and variations, and theforegoing examples of processes for which the invention may bebeneficially used, are intended to be illustrative and not for purposeof limitation. The invention is susceptible to still further variationsand alternative embodiments within the full scope of the invention,recited in the following claims.

What is claimed is:
 1. A system comprising: a glow discharge cellcomprising: an electrically conductive cylindrical vessel having a firstend and a closed second end, an inlet proximate to the first end, and anoutlet centered in the closed second end, a hollow electrode alignedwith a longitudinal axis of the electrically conductive cylindricalvessel and extending at least from the first end into the electricallyconductive cylindrical vessel, wherein the hollow electrode has an inletand an outlet, a first insulator that seals the first end of theelectrically conductive cylindrical vessel around the hollow electrodeand maintains a substantially equidistant gap between the electricallyconductive cylindrical vessel and the hollow electrode, and anon-conductive granular material disposed within the substantiallyequidistant gap, wherein the non-conductive granular material allows anelectrically conductive fluid to flow between the electricallyconductive cylindrical vessel and the hollow electrode, and thecombination of the non-conductive granular material and the electricallyconductive fluid prevents electrical arcing between the cylindricalvessel and the hollow electrode during an electric glow discharge; aplasma arc torch comprising: a cylindrical vessel having a first end anda second end, a tangential inlet connected to or proximate to the firstend, a tangential outlet connected to or proximate to the second end, anelectrode housing connected to the first end of the cylindrical vesselsuch that a first electrode is (a) aligned with a longitudinal axis ofthe cylindrical vessel, and (b) extends into the cylindrical vessel, ahollow electrode nozzle connected to the second end of the cylindricalvessel such that the center line of the hollow electrode nozzle isaligned with the longitudinal axis of the cylindrical vessel, andwherein the tangential inlet and the tangential outlet create a vortexwithin the cylindrical vessel, and the first electrode and the hollowelectrode nozzle create a plasma that discharges through the hollowelectrode nozzle; a linear actuator connected to the first electrode ofthe plasma arc torch to adjust a position of the first electrode withinthe cylindrical vessel along the longitudinal axis of the cylindricalvessel; a pump connected to a wastewater source; a first valve connectedto the pump; a compressed gas source connected to the first valve. athird valve connected between the outlet of the electrically conductivecylindrical vessel; an eductor having a first inlet, a second inlet andan outlet, wherein the first inlet is connected to the third valve, thesecond inlet is connected to the first valve, and the outlet isconnected to the tangential inlet of the plasma arc torch; and a secondvalve connected between the tangential outlet of the plasma arc torchand the inlet of the glow discharge cell, such that the plasma arc torchprovides the electrically conductive fluid to the glow discharge celland the glow discharge cell provides a treated water via the outletcentered in the closed second end.
 2. The system as recited in claim 1,wherein the non-conductive granular material is biochar, marbles,ceramic beads, molecular sieve media, sand, limestone, activated carbon,zeolite, zirconium, alumina, rock salt, nut shells or wood chips.
 3. Thesystem as recited in claim 1, further comprising a DC electrical powersupply electrically connected to: the glow discharge cell such that theelectrically conductive cylindrical vessel is an anode and the hollowelectrode is a cathode; and the plasma arc torch such that the firstelectrode is the anode and the hollow electrode nozzle is the cathode.4. The system as recited in claim 3, wherein the glow discharge cell andthe plasma arc torch have separate DC electrical power supplies.
 5. Thesystem as recited in claim 1, wherein the compressed gas source is a gascompressor.
 6. The system as recited in claim 1, wherein the plasma fromthe plasma arc torch is used for pyrolysis, gasification or water gasshift reactions.
 7. The system as recited in claim 6, wherein thegasification comprises gasifying a biomass.
 8. The system as recited inclaim 6, wherein the water gas shift reactions comprise producing syngasby a steam reforming process.
 9. The system as recited in claim 1,further comprising a pump disposed between the outlet of the hollowelectrode and the inlet of the electrically conductive cylindricalvessel.
 10. The system as recited in claim 1, further comprising acyclone separator connected to the hollow electrode nozzle of the plasmaarc torch.
 11. The system as recited in claim 6, further comprising ahydrocyclone connected to the second valve.